downhole counter balance effect toolalrdc.org/workshops/2014... · plunger. •on the down stroke...

10th Annual Sucker Rod Pumping

Workshop Renaissance Hotel

Oklahoma City, Oklahoma

September 16 - 19, 2014

Downhole Counter Balance Effect Tool

Joe Ippolito

LOTRAM LLC

(661) 599-7886

[email protected]

What I Will Show You Today

• Theory Behind the Tool.

• Tool Description.

• Modeling Used To Deploy the Tool.

• Tool Testing.

• Construction and Deployment

Issues.

• Benefits .

Sept. 16 - 19, 2014 2014 Sucker Rod Pumping Workshop 2

What Does It Do?

• Reduces Rod Loading

• Reduces PU Structural Loading

• Reduces Peak Gear Box Torque

• Reduces Power Consumption


How Does It Do It?

• The DH-CBE Utilizes the Pressure

Difference Between Inside the Tubing

And Outside the Tubing (Casing

Pressure) to Generate an Upward

Force.

• This Continuous Upward Force Acts as

a Counterbalance Effect.

Sept. 16 - 19, 2014

2014 Sucker Rod Pumping Workshop 4

Sept. 16 - 19, 2014 2014 Sucker Rod Pumping Workshop

5

How Does It Do It?

• The DH-CBE Would Typically be Deployed Below 1,200’

(See Fig. 1).

• Tubing Pressure at this Depth Would Be Approximately

500 PSI.

• Casing Pressure at the Same Depth Could Be as Little

as 2 PSI.

• That 498 PSI Difference Is Used to Power the DH-CBE.

DH–CBE Tool Placement


Figure 1

Description of DH-CBE

Tool Concept Is Illustrated In Fig. 2

• The DH-CBE Has an Internal Sliding Element.

• There are Plungers of Different Diameters at Each End.

• High Pressure Fluid is Internal to This Element.

• Low Pressure Gas is External.

• The Pressure Difference Pushes the Sliding Element

Upward.

• The Rods Are Landed On the Sliding Element.

• The Sliding Element Moves With the Rod String.


General Description


Patent Pending 8

Figure 2

Force Calculation


Figure 3

9

Source of Energy For DH-CBE

• Like Any Counterbalancing Method, Work is Added To And Removed From the System.

• On the Up Stroke the Fluid Works On the Plunger.

• On the Down Stroke the Plunger Works On the Fluid.

• Therefore the Energy/Work is Transferred In And Out of the Fluid.

• The Load Is Not Transfer To the Tubing. Tubing Pressure Remains Constant.


Reduces Rod Stress

• Rod Stress Above the DH-CBE are

Reduced By the Removal of Load.

• Rod Stress Below the DH-CBE Can Also

Be Reduced By Running Larger Diameter

Rods. The DH-CBE Stops That Extra Rod

Weight From Over Stressing the Rods

Above the DH-CBE.


Gearbox Torque Reductions

• The CBE Of Crank Mounted Counterweights Is

Not Constant Throughout the Entire Pumping

Cycle. The CBE Moves Between 0 % And 100%.

– This Can Be Seen By a Torsion Analysis of Two Dyno

Cards Having the Same PPRL and MPRL. Yet Peak

Torque Values are Different.

• This Can Be Also Be Seen With Reduced Peak

Torques When Using Air Balance Pumping Units.

– The CBE Effect of the Air Cylinder Induces a Relatively

Constant CBE Throughout the Stroke.


University Of Texas Torque_Factors_Kinematics

5000

10000

15000

20000

25000

0.0 0.2 0.4 0.6 0.8 1.0

Polis

hed R

od L

oad (

lbf)

Dimensionless Polished Rod Position

Polished Rod Dynamometer Card

PR Load

Permissible Load

PU: C320-298-100 Predicted

Base Case This Card Comes

With the U.T.

Spreadsheet


University Of Texas Torque_Factors_Kinematics

Modified

Base Case

U.T. Card (Same Peak and

Minimum Rod

Loads)

2000

7000

12000

17000

22000

27000

0.0 0.2 0.4 0.6 0.8 1.0

Polis

hed R

od L

oad (

lbf)



PR Load

Permissible Load

PU: C320-298-100


Torque Predictions Using U.T. Torque_Factors_Kinematics

DH-CBE PPRL MPRL PT *

LBS LBS LBS IN-LBS

Base Case ----------- 19,772 9,155 303,513

Base Case W/ DH-CBE 4,975 14,797 4,180 291,873

Reductions 25% 54% 3.8%

Modified Case ----------- 19,772 9,155 331,066

Modified Case w/ DH-CBE 4,975 14,797 4,180 306,307

Reductions 25% 54% 7.5%


* Spreadsheets also predict less periods and smaller values of negative torque.

PU: C320-298-100

Comparison of Unit Types With Dynamometer Cards


5000

10000

15000

20000

25000

0.0 0.5 1.0

Polis

hed R

od L

oad (

lbf)



PR Load

Permissible Load

Conventional PU:C320-298-100 Air Balance PU:C320-305-100

5000

10000

15000

20000

25000

0.000 0.500 1.000

Po

lish

ed

Ro

d L

oad

(lb

f)



PR Load

PermissibleLoad

Peak Torque 303,513 IN-LB Peak Torque 205,378 IN-LB

PERFORMANCE MODELING


Performance Objectives

• Place the Tool Deep Enough to Generate

The Needed Forces. Deeper (Higher

Pressure) Produces Greater Forces.

• Placing the Tool Too Deep May Induce

Buckling Above the Tool. The Rods

Below the DH-CBE Need to Pull the Tool

Down.

Sept. 16 - 19, 2014


Performance Modeling

• Model the Rod String Suspended Below the DH-CBE

to Determine Rod Loading at That Point.

– Adjust Flowline Pressure to Match Tool Depth.

– To Prohibit Buckling We Try to Induce a MPRL Greater Than

DH-CBE Upward Force. Much Like Prohibiting Rod Floating

at Surface.

– Some Applications May Tolerate Light Compression, Much

Like We See Above Some Pumps.

• 1” Rods in 2 7/8” Tubing Would Be More Tolerant of

Compression.

• Can Also Use Centralizers .


Performance Modeling

• Model the Entire Rod String Without the DH-CBE

to Determine:

– Displacement, It Will Be Understated Because of

Reduced Rod Stretch.

– Model Top Rod Stress Than Reduce it By Applying the

DH-CBE Load Reduction.

– Intending to Develop a Wave Equation Model That Can

Include DH-CBE Forces.

• Take Prior Dynamometer and Adjust for DH-CBE

Load Reductions and Added Rod Weight.

– Conduct Torsion Analysis on Modified Card.


Proof of Concept - Testing Results


Field Testing

• Installed On April 22, 2013 In the Bellevue Field,

Bakersfield, Ca.

• C320-213-75 PU, 6.6 SPM, 2.75” Pump, 87 Rod String

• A Highly Deviated Well With 7” Casing, Tool O.D. was

5.25”.

• Top Perforation is at 7,096 Feet, Pump Depth was at

4,680 Feet.

• High Water Cut 98.5%.

• High GOR, Observed But Not Measured.


Testing History

• Dynamometer Analysis Was Performed

Before and After Engaging the Tool.

• These Comparisons Were Made While Using

the Same New Rod Pump.

• DH-CBE Sized For 5,000 LBS.

• Well Went Down In Dec 2013 With a Hole In

the Tubing.

• DH-CBE Removed in June 2014, Found 3

Failed Joints.


Testing History

• We Did Not Return the Well to Production

With the DH-CBE.

• Test Well Was Not Overloaded.

• Tested at the Same Displacement.

• The Operator Did Not Want to Increase

Displacement at That Time. They Have

Limited Waste Water Injection Capacity.

• Did Not Need The DH-CBE Without a

Production Increase.

Sept. 16 - 19, 2014


Before & After Dynamometers

Polished-Rod Stroke (Inches) 0 76.2

Polis

hed-R

od L

oad (

Pounds) 20,545

15,952

6,545

1,597

20,000

15,000

10,000

5,000

0

Before

After


BEFORE AFTER Diff.

Polished-Rod PPRL 20,545 15,952 -4,593 LBS

MPRL 6,545 1,597 -4,948 LBS

Diff 14,000 14,355 355 LBS

Mod Goodman

Diagram (.8) D Rods 97 84 -13 %

Rod Stress Max 26,158 20,310 -5,848 PSI

Min 8,333 2,033 -6,300 PSI

Rod Stretch 21.90 20.10 -1.80 IN

Plngr Stk 61.80 64.50 2.70 IN

Ovr-Trvl 7.50 8.30 0.80 IN

Valve Ck Load TV 17,716 12,363 -5,353 LBS

SV 9,401 4,753 -4,648 LBS

Diff 8,315 7,610 -705 LBS

Dynamometer Test Analysis


Reductions

PU Structural Loading 22%

Stress - Upper Rods 13%

Gearbox Peak Torque 9%

Results Summary


Reductions will increase with deeper wells.

Fluid Leakage Through Tool

• Looked For a Reduction in Well Tests.

– Rate Variations With Changes in SPM Made It Difficult

To Compare Before and After Well Tests. The Well Has

a Natural Gas Engine.

– Monthly Production Rates Appear Unaffected, See the

Following Plot.

• Looked at Tubing Pressure Tests

– There Was A Very Slow or No Drop In Tubing Pressure

During Pressure Test.

– However Tubing Contained Relatively High Gas

Volumes.

• Fluid Leakage Did Not Appear To Be a Problem.

Sept. 16 - 19, 2014


Test Well Production


0

50

100

150

200

250

BFPD

BFPD

Replaced Pump

Removed DH-CBE

Found Holes in Tubing

Installed DH-CBE Did not replace pump. Before & After Dyno

Construction & Installation Issues

• The DH-CBE is Constructed with Sucker

Rod Pump Plungers and Barrels.

– Largest O.D. 5.25”.

• Larger Than the Pump But Smaller than

Tubing Anchor

• Is Hung Shallow.

• The DH-CBE is Full I.D. Therefore it Does

Not Interfere with Running Any Downhole

Equipment.


Construction & Installation Issues

• We Recommend Using the Same Methods for

Solids and Corrosion Control as the Downhole

Pump. The DH-CBE Operates at Much Lower

Pressures and Therefore Should Last Longer

and Have Less Slip.

• A Landing Tool, Installed In the Rod String

Engages the DH-CBE. It Need Not Latch, the

Generated Forces Keep the DH-CBE Engaged.


Running Procedure

1. Run the downhole pump assembly.

2. Run sufficient tubing to meet spacing requirement

between DH-CBE and pump.

3. Run DH-CBE

4. Run sufficient tubing to place pump at depth.

5. Run pump and rods matching spacing in step 2 above.

6. Run landing tool.

7. Run rods and space pump.


DH-CBE Landing Tool

The landing tool

naturally seats in the

DH-CBE and pulls free.


DH-CBE Landing Tool


The Landing Tool

Naturally Seats in the

DH-CBE and Pulls Free.

DH-CBE Benefits

• Pump displacements Can Be Increased.

• Pumps Can be Run Deeper.

• Reduced Rod Parts.

• Reduced Energy Consumption.

– Savings from mechanical inefficiencies and electrical resistance

losses.

– Reduced back generated power .



Copyright

Rights to this presentation are owned by the company(ies) and/or author(s) listed on the title page. By submitting this presentation to the Sucker Rod Pumping Workshop, they grant to the Workshop, the Artificial Lift Research and Development Council (ALRDC), and the Southwestern Petroleum Short Course (SWPSC), rights to:

– Display the presentation at the Workshop.

– Place it on the www.alrdc.com web site, with access to the site to be as directed by the Workshop Steering Committee.

– Place it on a CD for distribution and/or sale as directed by the Workshop Steering Committee.

Other use of this presentation is prohibited without the expressed written permission of the author(s). The owner company(ies) and/or author(s) may publish this material in other journals or magazines if they refer to the Sucker Rod Pumping Workshop where it was first presented.

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Disclaimer

The following disclaimer shall be included as the last page of a Technical Presentation or Continuing Education Course. A similar disclaimer is included on the front page of the Sucker Rod Pumping Web Site.

The Artificial Lift Research and Development Council and its officers and trustees, and the Sucker Rod Pumping Workshop Steering Committee members, and their supporting organizations and companies (here-in-after referred to as the Sponsoring Organizations), and the author(s) of this Technical Presentation or Continuing Education Training Course and their company(ies), provide this presentation and/or training material at the Sucker Rod Pumping Workshop "as is" without any warranty of any kind, express or implied, as to the accuracy of the information or the products or services referred to by any presenter (in so far as such warranties may be excluded under any relevant law) and these members and their companies will not be liable for unlawful actions and any losses or damage that may result from use of any presentation as a consequence of any inaccuracies in, or any omission from, the information which therein may be contained.

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The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond the source documents, although we do make every attempt to work from authoritative sources. The Sponsoring Organizations provide these presentations and/or training materials as a service. The Sponsoring Organizations make no representations or warranties, express or implied, with respect to the presentations and/or training materials, or any part thereof, including any warrantees of title, non-infringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose.

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